Latex compositions containing ethylenically unsaturated esters of long-chain alkenols and applications thereof

ABSTRACT

Novel latex or emulsion compositions containing internally plasticizing and crosslinkable long-chain alkenol ester monomers are disclosed and claimed. Preferred embodiments include latex formed from acrylate or methacrylate esters of long-chain alkenols. A process for the synthesis of the latex composition is also disclosed, which involves (a) esterification of a long-chain alkenol with an ethylenically unsaturated carboxylic acid; (b) polymerization of the ethylenically unsaturated ester in an aqueous phase with at least one other copolymerizable monomer; and (b) blending of so formed polymer with at least one drier and a surfactant to form the novel latex or emulsion compositions. These compositions form films at low minimum film forming temperatures (MFT) ranging from −5 to 10° C. and cure to above ambient glass transition (T g ) polymers without the use of traditional organic cosolvents which contribute to environmental pollution via volatile organic compounds (VOCs) emissions. These compositions are therefore useful in waterborne coatings, contact and pressure sensitive adhesives, and inks.

This is a divisional of application Ser. No. 08/773/670 filed Dec. 24, 1996, now U.S. Pat. No. 6,001,913.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to odorless and organic solvent-free novel waterborne latex or emulsion compositions which contain an internally plasticizing and cross-linkable monomer(s) having at least one double bond in its backbone. More particularly, though not exclusively, this invention relates both to novel latex or emulsion compositions containing a substituted or unsubstituted acrylic ester of a long-chain alkenol and a process for making the same. The invention is also directed to the utility of these novel compositions in coatings, adhesives, and inks which have essentially no volatile organic components (VOCs) and feature enhanced application and performance properties.

2. Description of the Prior Art

Recent Congressional enactments have forced coatings manufacturers to develop new coating formulations that contain low VOCs yet feature good performance properties. However, attempts at developing new formulations that contain environmentally acceptable low VOCs have only resulted in formulations with poor performance characteristics which are also economically unattractive.

One problem encountered by the coatings manufacturers is the development of formulations containing low VOC-coalescing aids or plasticizers. For instance, emulsion polymers are currently formulated with coalescing aids or plasticizers in order to form films at and below ambient conditions yet dry to films of sufficient glass transition temperature (T_(g)) to perform adequately at and above room temperature. In general, the ability of emulsion polymers to form or coalesce into film is governed by the minimum film forming temperature (MFT) of the polymer in question, which typically approximates T_(g) of that polymer. Thus, there is a dilemma, i.e., low MFT polymers are required in order to exhibit coalescence, flow, and surface wetting properties. However, if the polymer remains soft and tacky, the coatings are not usable. Therefore, it is necessary to develop a technology in which coating formulations contain suitable ingredients with an initial low MFT, followed upon application forms nontacky, durable, hard, and water resistant surfaces having a T_(g) significantly above their MFT.

There are few references in literature which describe low MFT coating compositions which cure to form high T_(g) films. One such example utilizes a terpolymer binder known as Vinamul 3692, which is used in solventless paints. The terpolymer is formed from ethylene, vinyl acetate, and acrylated ethylene vinyl acetate. Although the physical properties of the paint films are generally good, the latex synthesis involves the use of ethylene in high pressure reactors. Such a manufacturing protocol is not available to most latex manufacturers and is not cost effective.

There have been many other reports that disclose coatings compositions that cure or dry at ambient conditions into durable products. For example, vinylic derivatives of auto-oxidizable drying oils have been synthesized, which are formulated into crosslinkable emulsion compositions. However, these emulsion compositions still required the use of VOCs for film formation and formulation into usable coatings. Moreover, the polymers possessed other drawbacks, i.e., the free radical polymerizations of vinyl monomers of high iodine number oils are kinetically unfavorable and the products exhibit moderate to marked incompatibility.

Various other coating compositions which cure under ambient conditions are known in the prior art. A few such examples involve curing by a chemical reaction such as epoxide-carboxylic acid reaction, isocyanate-moisture reaction, polyaziridine-carboxylic acid reaction, and activated methylene-unsaturated acrylic reaction.

There are also literature references which disclose derivatives of fatty compounds suitable in the formation of coatings. For example, acryloxymethyl substituted fatty compounds have been claimed to be useful in radiation curable coating formulations and as binders in inks. Acrylate esters of castor oil have also been reported to be potentially useful as binders in coatings and other applications.

However, none of these references discloses use of an internally plasticizing and crosslinkable long-chain alkenol monomer for the formation of coating formulations. In addition, none of the references discussed above utilizes inexpensive and readily available acrylate or other ethylenically unsaturated esters of long-chain alkenols to form latex or emulsion compositions. Furthermore, none of the references mentioned above describes latex or emulsion compositions featuring low MFTs that cure to above ambient T_(g) without the use of any VOCs and yet featuring enhanced properties.

Therefore, it is an object of this invention to provide novel compositions having low VOCs and low odor which are suitable for forming coatings, adhesives, and inks formulations comprising an internally plasticizing and crosslinkable long-chain alkenol monomer. An additional objective of this invention is to provide a process for the synthesis of the novel latex or emulsion compositions. Yet another objective of this invention is to provide a variety of utilities for these novel compositions. Such utilities include as a binder in coatings, adhesives, and inks formulations featuring enhanced properties yet contributing zero VOCs. The compositions of the present invention have no precedence in the prior art.

Prior Art

The following references are disclosed as background art and for informational purpose.

U.S. Pat. No. 4,626,582 discloses acyloxymethyl fatty compounds which are useful as monomers in the preparation of radiation curable coatings.

U.S. Pat. No. 4,826,907 discloses an acrylic or methacrylic resin emulsion coating composition, and its use.

U.S. Pat. No. 4,906,684 discloses ambient curing coating compositions which are made from aqueous dispersions of copolymers of acetoacetoxyethyl acrylate or methacrylate, glycidyl acrylate or methacrylate, and ethylenically unsaturated polymerizable acid and a different monomer copolymerizable therewith.

Eur. Pat. Appln. No. 466,409 discloses a polymer blend useful as a binder in an aqueous coating composition containing no coalescent.

Indian Pat. No. 153,599 describes a process for preparing novel vinyl monomers from ricinoleic acid and mixed fatty acids of castor oil.

Indian Pat. No. 154,467 describes a process for the preparation of novel acrylic monomers and polymers from castor oil and methyl ricinoleate.

J. American Oil Chem. Soc., (1966) (pp 542-545) describes synthesis of acrylate esters of various hydroxy acid derivatives obtainable from castor oil.

All of the references described herein are incorporated herein by reference in their entirety.

SUMMARY OF THE INVENTION

Surprisingly, it has now been found that coatings, adhesives and inks having essentially no VOCs can readily be formed from novel latex or emulsion compositions. In addition, the novel compositions of the present invention are comprised of a monomer which features a plasticizing property, and thus serves as an internal plasticizer and subsequently as a crosslinking agent. The monomers suitable for forming the latex or emulsion compositions of this invention are ethylenically unsaturated carboxylic acid esters of long-chain alkenols. Preferred monomers of this invention are acrylate or methacrylate esters of long-chain alkenols. The latices formed by this invention have utility in numerous applications such as in coatings, adhesives, and inks formulations.

Accordingly, the present invention provides a composition having low volatile organics content and low odor that is suitable for forming coatings, adhesives, and inks formulations comprising an aqueous dispersion composed of a blended mixture of:

-   -   (a) a polymer obtained by the polymerization of:         -   (i) an internally plasticizing and crosslinkable long-chain             alkenol ester monomer having at least one double bond in             said alkenol long-chain; and         -   (ii) one or more of ethylenically unsaturated monomers             copolymerizable therewith;     -   (b) a drier selected from the group consisting of aliphatic         carboxylic acid salts of cobalt, manganese, lead, zirconium,         calcium, and mixtures thereof; and     -   (c) a surface-active agent; wherein the total weight percent of         the polymer in the aqueous dispersion is at least from about 5         and not more than about 80 weight percent, wherein the         monomers (i) and (ii) are present in the weight ratio ranging         from about 1:2 to about 1:99.

In another aspect of the present invention, a process for the formation of a waterborne formulation for coatings, inks or adhesives containing a polymer formed from an ethylenically unsaturated ester of a long-chain alkenol is also provided.

DETAILED DESCRIPTION OF THE INVETION

Surprisingly, it has now been found that coatings, adhesives and inks having essentially no VOCs can readily be formed from novel latex or emulsion compositions. In addition, the novel compositions of the present invention are comprised of a monomer which features a plasticizing property, and thus serves as an internal plasticizer and subsequently as a crosslinking agent. The monomers suitable for forming the latex or emulsion compositions of this invention are ethylenically unsaturated carboxylic acid esters of long-chain alkenols. Preferred monomers of this invention are acrylate or methacrylate esters of long-chain alkenols. The latices formed by this invention have utility in numerous applications such as in coatings, adhesives, and inks formulations.

Accordingly, the present invention provides a composition having low volatile organics content and low odor that is suitable for forming coatings, adhesives, and inks formulations comprising an aqueous dispersion composed of a blended mixture of

-   -   (a) a polymer obtained by the polymerization of         -   (i) an internally plasticizing and crosslinkable long-chain             alkenol ester monomer having at least one double bond in             said alkenol long-chain; and         -   (ii) one or more of ethylenically unsaturated monomers             copolymerizable therewith;     -   (b) a drier selected from the group consisting of aliphatic         carboxylic acid salts of cobalt, manganese, lead, zirconium,         calcium, and mixtures thereof, and     -   (c) a surface-active agent; wherein the total weight percent of         the polymer in the aqueous dispersion is at least from about 5         and not more than about 80 weight percent, wherein the         monomers (i) and (ii) are present in the weight ratio ranging         from about 1:2 to about 1:99.

As used herein, the term internally plasticizing monomer is intended to be generic to a class of compounds wherein the monomers of this invention are capable of polymerizing and at the same time act as a plasticizer (i.e., “in-chain” or “internal plasticization”) for the polymer formed therefrom. Generally, the coatings formulations contain a volatile organic solvent additive(s) that acts as a plasticizer for the polymeric binder. The role of these volatile organic plasticizers is to reduce the apparent T_(g) of the polymer thereby permitting the coating to form a useful film at a temperature below the real T_(g) of the polymer. Thus, by incorporating the internally plasticizing monomers of the present invention, the polymers or copolymers formed in this invention are self plasticized with no subsequent VOC emissions. As a result, the compositions of the present invention which are suitable for forming coatings, adhesives, and inks exhibit lower minimum film forming temperatures (MFTs) than the corresponding T_(g)'s of the cured compositions.

Additionally, the internally plasticizing monomers of the present invention are also capable of crosslinking during the drying process. The term crosslinking used herein is intended to mean that the monomers of the present invention are capable of bonding to itself, and/or another compound or polymeric chain triggered by a suitable chemical or physical reaction. In a typical coating formulation, for example, the formulation is first applied onto a desired surface and then cured by suitable means during which time the crosslinking of the polymeric binder occurs. Thus, the monomers of the present invention may be crosslinked after forming films from the coating compositions. Curing can be affected by a wide variety of well known techniques in the art.

The internally plasticizing and crosslinkable monomers of the present invention are preferably long-chain alkenols having at least one double bond and an aliphatic chain of about at least 10 carbon atoms. Various substituted or unsubstituted longchain alkenols may be used in this invention. Representative examples of suitable longchain alkenols are deca4-ene-1-ol, undeca-6-ene-1-ol, dodeca-8-ene-1-ol, trideca-7-ene-1-ol, tetradeca-3-ene-1-ol, pentadeca-12-ene-1-ol, hexadeca-10-ene-1-ol, heptadeca-14-ene-1-ol, octadeca-5-ene-1-ol, nonadeca-11-ene-1-ol, 3-methyl-deca-5-ene-1-ol, 4-ethyl-undeca-7-ene-1-ol, 8-propyl-dodeca-3-ene-1-ol, 4-butyl-trideca-6-ene-1-ol, 3-propyl-tetradeca-5-ene-1-ol, 5-butyl-pentadeca-11-ene-3-ol, 6-pentyl-hexadeca-9-ene-2-ol, 12-methyl-heptadeca-9-ene-4-ol, 3-ethyl-octadeca-5-ene-4-ol, 6-butyl-nonadeca-14-ene-5-ol, hexadeca-6-ene-3-ol, 3-methyl-hexadeca-6-ene-4-ol, octadeca-7-ene-4-ol, nonadeca-8-ene-2-ol, hexadeca-5-7-diene-2-ol, hexadeca-5-10-diene-2-ol, eicosa-6-12-diene-3-ol, docosa4-7-diene-1-ol, and hexacosa-13-15-diene-4-ol.

Accordingly, the preferred internally plasticizing and crosslinkable monomers of the present invention are substituted ethylenically unsaturated esters of long-chain alkenols of the formula I:

-   -   wherein (a) R₁, R₂, R₃, R4, R₅, R₆, and R₇, are the same or         different and are each independently selected from the group         consisting of:         -   hydrogen;         -   alkoxy group having 1 to 10 carbon atoms;         -   alkoxyalkyl group having 1 to 10 carbon atoms; and         -   linear or branched alkyl and fluoroalkyl groups having the             formula C_(n)H_(x)F_(y),     -   where n is an integer from 1 to 10, x and y are integers from 0         to 2n+1, and the sum of x and y is 2n+1;     -   (b) R₈, R₉, and R₁₀ are the same or different and are         independently selected from the group consisting of:         -   hydrogen;         -   a carboxylate of the formula —COOR, where R is alkyl group             having 1 to 10 carbon atoms, or phenyl and substituted             phenyl;         -   phenyl and substituted phenyl;         -   tolyl and substituted tolyl;         -   benzyl and substituted benzyl;         -   a linear or branched alkenyl group having 2 to 10 carbon             atoms; and         -   linear or branched alkyl and fluoroalkyl groups having the             formula C_(n)H_(x)F_(y),     -   where n is an integer from 1 to 8, x and y are integers from 0         to 2n+1, and the sum of x and y is 2n+1; and     -   (c) a, b, and c, are integers, where a and c have a value of         from 0 to 20, and sum of a and c is at least 8, and b has a         value of 1 or 2.

In the above definitions and throughout the present specification, alkoxy means straight or branched chain alkoxy having 1 to 10 carbon atoms, and includes, for example, methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, tert-butoxy, pentyloxy, hexyloxy, heptyloxy, octyloxy, nonanyloxy, decanyloxy, 4-methylhexyloxy, 2-propylheptyloxy, and 2-ethyloctyloxy.

Alkoxyalkyl means that the alkoxy moiety and the alkyl moiety each are straight or branched chains having 1 to 10 carbon atoms, and includes, for example, methoxymethyl, ethoxymethyl, propoxymethyl, isopropoxymethyl, butoxymethyl, isobutoxymethyl, tert-butoxymethyl, pentyloxymethyl, hexyloxymethyl, heptyloxymethyl, octyloxymethyl, decyloxymethyl, 2-methoxyethyl, 2-ethyloxyethyl, 2-propoxyethyl, 2-butoxyethyl, 2-hexyloxyethyl, 2-octyloxyethyl, 2-nonyloxyethyl, 3-methoxypropyl, 3-ethoxypropyl, 3-propoxypropyl, 3-butoxypropyl, 3-hexyloxypropyl, 3-octyloxypropyl, 3-decyloxypropyl, 4-methoxybutyl, 4-ethoxybutyl, 4-propoxybutyl, 4-butoxybutyl, 4-hexyloxybutyl, 4-octyloxybutyl, 4-nonyloxybutyl, 5-methoxypentyl, 5-ethoxypentyl, 5-propoxypentyl, 5-butoxypentyl, 5-pentyloxypentyl, 5-hexyloxypentyl, 5-octyloxypentyl, 5-decyloxypentyl, 6-methoxyhexyl, 6-ethoxyhexyl, 6-propoxyhexyl, 6-butoxyhexyl, 6-pentyloxyhexyl, 6-hexyloxyhexyl, 6-octyloxyhexyl, 6-decyloxyhexyl, 8-methoxyoctyl, 8-ethoxyoctyl, 8-butoxyoctyl, 8-hexyloxyoctyl, 8-octyloxyoctyl, 10-methoxydecyl, 10-propoxydecyl, 10-pentyloxydecyl, and 10-decyloxydecyl.

Hydroxyalkyl means a hydroxy containing straight or branched chain alkyl group having 1 to 10 carbon atoms, and includes, for example, hydroxymethyl, 2-hydroxyethyl, 1-hydroxyethyl, 3-hydroxypropyl, 2-hydroxypropyl, 4-hydroxybutyl, 3-hydroxy-3-methylpropyl, 5-hydroxypentyl, 4-hydroxy-3-methylbutyl, 6-hydroxyhexyl, 8-hydroxyoctyl, and 10-hydroxydecyl.

Acyloxyalkyl means that acyloxy moiety and the alkyl moiety each are straight or branched chains having 1 to 10 carbon atoms, and includes, for example, acetoxymethyl, acryloxymethyl, methacryloxymethyl, propionoxymethyl, acetoxyethyl, acryloxyethyl, butyroxyethyl, acetoxybutyl, acryloxybutyl, hexanoyloxybutyl, acetoxyhexyl, acryloxyhexyl, octanoyloxyhexyl, acetoxyoctyl, acryloxyoctyl, acetoxydecyl, and acryloxydecyl.

Substituted phenyl, tolyl, and benzyl means phenyl, tolyl, or benzyl ring substituted by at least one suitable substituent group selected from the group consisting of amino, nitro, hydroxy, straight or branched alkoxy group such as methoxy, straight or branched alkyl and/or fluoroalkyl group such as methyl, trifluoromethyl, alkenyl group such as vinyl, and halogen (fluorine, chlorine, bromine or iodine).

Representative examples of linear or branched alkyl and fluoroalkyl groups having 1 to 10 carbon atoms include, for example, methyl, trifluoromethyl, ethyl, 1,1,2-trifluoroethyl, pentafluoroethyl, propyl, perfluoropropyl, isopropyl, butyl, isobutyl, tert-butyl, perfluorobutyl, 1,1,2,3,3-pentafluorobutyl, pentyl, hexyl, heptyl, octyl, nonyl, and decanyl.

Linear or branched alkenyl means alkenyl moiety having 2 to 10 carbon atoms, and includes, for example, vinyl, 1-propenyl, allyl, isopropenyl, 2-butenyl, 1,3-butadienyl, 2-pentenyl, 2-hexenyl, 2-octenyl, 3-nonenyl, and 4-decenyl.

Furthermore, and as used herein, the term “substituted” is contemplated to include all permissible substituents of organic compounds. In a broad aspect, the permissible substituents include acyclic and cyclic, branched and unbranched, carbocyclic and heterocyclic, aromatic and non-aromatic substituents of organic compounds. Illustrative substituents include, for example, those described hereinabove. The permissible substituents can be one or more and the same or different for appropriate organic compounds. For purposes of this invention, the heteroatoms such as nitrogen may have hydrogen substituents and/or any permissible substituents of organic compounds described herein which satisfy the valencies of the heteroatoms. This invention is not intended to be limited in any manner by the permissible substituents of organic compounds.

A wide variety of ethylenically unsaturated carboxylic acid or its derivatives may be used for the formation of desired starting materials of the present invention. The compounds having at least one polymerizable ethylenic bond per molecule (i.e., a double bond) are preferred. Representative examples of such ethylenically unsaturated carboxylic acids include, without limitation, acrylic, methacrylic, maleic, fumaric, itaconic, ethacrylic, crotonic, citraconic, cinnamic, methyl hydrogen fumarate, benzyl hydrogen maleate, butyl hydrogen maleate, octyl hydrogen itaconate, and dodecyl hydrogen citraconate. Preferred ethylenically unsaturated carboxylic acids for forming the esters of the long-chain alkenols are acrylic and methacrylic acids or its derivatives.

The compositions containing the long-chain alkenols of the present invention further consists of at least one copolymerizable monomer. Such a copolymerizable monomer include, broadly, polymerizable acid monomer, a monomer containing at least one ethylenically unsaturated polymerizable group, and various other ethylenically unsaturated monomers well known in the art.

Polymerizable acid monomers used in this invention are the well known mono- or polycarboxylic acids which contain one polymerizable bond per molecule. Examples of such acids are acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, ethacrylic acid, crotonic acid, citraconic acid, and half esters of the dicarboxylic acids wherein the esterified alcohol group contains from 1 to about 20 carbon atoms. Examples of suitable half esters are methyl hydrogen maleate, methyl hydrogen fumarate, benzyl hydrogen maleate, butyl hydrogen maleate, octyl hydrogen itaconate, dodecyl hydrogen citraconate, and the like. Carboxylic acid anhydrides such as maleic anhydride can also be used. The preferred acids for use in this invention as comonomers are acrylic and methacrylic acids.

Copolymerizable monomers that contain at least one ethylenically unsaturated polymerizable group referred to hereinabove are any of the well known monomers which contain at least one ethylenically unsaturated polymerizable group per molecule and are copolymerizable with the other monomers. Examples of such monomers are acrylic and methacrylic esters wherein the ester group contains 1 to about 20 carbon atoms, e.g., methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, isopropyl acrylate, isopropyl methacrylate, butyl acrylate, butyl methacrylate, 2-ethylhexyl methacrylate, decyl acrylate, lauryl methacrylate, benzyl acrylate, and the like. Esters of various other unsaturated acids include butyl fumarate, octyl fumarate, butyl maleate, and octyl maleate.

Other acrylic or methacrylic esters which can be used in this invention are multifunctional acrylates or methacrylates, and includes, for example, propylene glycol monoester of acrylic acid, propylene glycol monoester of methacrylic acid, ethylene glycol monoester of acrylic acid, ethylene glycol monoester of methacrylic acid, glycidyl acrylate, glycidyl methacrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, and hexanediol diacrylate.

Other copolymerizable monomers are vinyl aromatic monomers, such as styrene, para-acetoxystyrene, vinyl toluene, alpha methyl styrene, vinyl pyridine and the like as well as nitriles and amides, e.g., acrylonitrile and acrylamide. Other olefinic monomers such as ethylene, propylene, and butadiene are also suitable comonomers for this invention.

Additional copolymerizable monomers that can be used in this invention are the derivatives of the hypothetical vinyl alcohol, i.e., aliphatic vinyl esters such as vinyl formate, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl heptanoate, vinyl pelargonate, vinyl 3,6-dioxaheptanoate, vinyl 3,6,9-trioxaundecanoate, the vinyl ester of versatic acid (sold under the tradename Veova 10™), vinyl esters of neo acids and the like. Other vinyl monomers such as vinyl chloride, vinyl sulfonate, vinyl silanes, and vinylidene chloride are also suitable comonomers.

Various other copolymerizable monomers that impart enhanced properties to the resulting compositions of the present invention may also be used. One such example is a wet adhesion promoter which improves adhesion of the compositions to a wide variety of substances including wood, plastic, and metal surfaces. Illustrative examples of such wet adhesion promoting monomers include dimethylaminoethyl methacrylate, methacrylamidoethylethyleneurea (sold under the tradename Sipomer® WAM II by Rhone-Poulenc), acrylamidoethylethyleneurea, 3-isopropenyl-α,α-dimethylbenzyl isocyanate, and styrene sulfonate.

Any monomers which are copolymerizable with the ethylenically unsaturated long-chain olefinic monomer I of this invention can be used in this invention. Such monomers are those which contain no groups which are reactive under polymerization conditions with any of the other reactive groups that may be present in I. Thus, suitable comonomers may be employed depending upon the groups present in the long-chain monomer I.

The types and amounts of copolymerizable monomers used in this invention will vary depending on the particular end use for which the product of this invention is intended. Such variations are well known and can be readily determined by those skilled in the art. In general, the weight percents of the polymer containing the internally plasticizing compound, i.e., the long-chain monomer I and the copolymerizable monomer in the resulting composition ranges from about 5 and not more than about 80 weight percent based upon the total weight of the composition. Preferably, the total weight percents of the polymer range from about 30 to about 70 weight percent based on the total weight of the composition. The weight ratio of the long-chain monomer 1 to the copolymerizable monomer (s) generally range from about 1:2 to about 1:99, preferably the weight ratio range from about 1:7 to about 1:20.

In addition to the polymeric resins formed from the monomer I and the comonomers mentioned hereinabove, the coatings or adhesives or inks compositions of the present invention contain at least one drier. The driers are materials that promote or accelerate the curing or hardening of film formers. Typically, driers are used in conjunction with coatings formulations containing the drying oil components. Surprisingly, it has now been found that the metal driers are particularly effective in curing the compositions of the present invention which contain no drying oil components.

The suitable drier is any material which will function as a promoter or an accelerator for the curing or hardening of the film and includes, without limitation, neutral soaps of the formula (R_(x)—COO⁻)₂M²⁺ or (R_(x)—COO⁻)₃M³⁺; acid soaps of the formula (R_(x)—COO⁻)₂M²⁺. R_(x)—COOH or (R_(x)—COO⁻)₃M³⁺. R_(x)—COOH; basic soaps of the formula (R_(x)—COO⁻)₂M²⁺. OH; organic complexed or mixed soaps of the formula (R_(x)—COO⁻)(R′_(x)—COO⁻)M²⁺ or (R_(x)—COO⁻)(R′_(x)—COO⁻)(R″_(x)—COO⁻)M³⁺; inorganic/organic complexed or mixed soaps of the formula O—M²⁺ —O—CO—R_(x), X—O—M²⁺ —O—CO—R_(x), and O—M²⁺ —O—CO—R_(x); where R_(x)—COO⁻, R′_(x)—COO⁻, and R″ _(x)—COO⁻ are aliphatic carboxylic acid ions having 6 to 20 carbon atoms, M=metal ion, and X=phosphorus or boron.

The commonly used carboxylic acids for forming the metal driers are aliphatic acids, preferably fatty acids. Illustrative examples of fatty acids include rosin oil fatty acid, linseed oil fatty acid, and tall oil fatty acid. Various naphthenic acids obtained from certain petroleum crudes may also be used for forming the suitable metal driers. The naphthenic acids generally contains an average of 12-14 carbon atoms having a yclopentane nucleus with the carboxyl group terminating a side chain and with one to hree methylenic groups between the carboxyl and the nucleus. Various other synthetic acids having 8 to 10 carbon atoms are also used to form the metal driers, and include, for example, 2-ethylhexanoic acid and neodecanoic acids.

The most commonly used drier metals are cobalt, zirconium, manganese, calcium and lead. Other metals such as zinc, copper, barium, vanadium, cerium, iron, potassium, strontium, aluminum, bismuth, and lithium have also been used as drier metals. Particularly preferred metal driers are aliphatic carboxylic salts of cobalt, manganese, lead, zirconium, calcium, and mixtures thereof It has been found that cobalt salts sold under the tradename Co Hydro-Cure® II are particularly preferred metal driers for the compositions of the present invention. A detailed description of various metal driers may be found in “Surface Coatings-Raw Materials and Their Usage,” Vol. 1, Chapman & Hall, Chapter 33, pp 592-606 (1993), incorporated herein by reference in its entirety.

Although metal driers mentioned hereinabove are particularly effective in the drying of the films, various other non-metallic driers well-known in the art may also be employed either as primary driers, auxiliary driers, or as drier accelerators. Many auxiliary non-metallic driers are effective in improving the solubility of the active drier metal in the reactive medium or alter the drier metals redox potential. Examples of such non-metallic driers include 8-hydroxyquinoline, quinoline, salicyl aldoxime, pyridine-2-carbaldoxime, acetylacetonate enamines, 2-2′-bipyridyl, ethylenediamine, propylenediamine, pyridine, o-vinylpyridine, o-aminopyridine, aniline, o-phenylenediamine, o-toluidine, α-naphthylamine, o-phenanthroline, dipropylamine, diamylamine, acrylonitrile, succinonitrile, o-tolunitrile, o-toluamide, o-tolyl isocyanate, phenyl isocyanate, naphthyl isocyanate, pyrrole, benzimidazole, benzotriazole, and the like. Particularly preferred non-metallic drier is 2-2′-bipyridyl sold under the tradename DRI-RX™.

As described hereinbelow, the compositions of this invention are prepared by polymerization of monomers emulsified in water using conventional emulsion polymerization procedures. A suitable surface-active agent generally known as surfactants are used for emulsification of the monomers. Suitable surfactants include cationic, anionic, amphoteric, or nonionic surfactants or mixtures thereof

Examples of useful anionic surfactants are organosulfates and sulfonates, e.g., sodium and potassium alkyl, aryl, and aralkyl sulfates and sulfonates, such as sodium 2-ethylhexyl sulfate, potassium 2-ethylhexyl sulfate, sodium nonyl sulfate, sodium lauryl sulfate, potassium methylbenzene sulfonate, sodium dodecylbenzene sulfonate, potassium toluene sulfonate and sodium xylene sulfonate; higher fatty alcohols, e.g., stearyl, lauryl, etc., which have been ethoxylated and sulfonated; dialkyl esters of alkali metal sulfosuccinic acid salts, such as sodium diamyl sulfosuccinate, sodium dioxtyl sulfosuccinate, and sodium dioctyl sulfosuccinate, formaldehyde-naphthalene sulfonic acid condensation products; and alkali metal salts, partial alkali metal salts and free acids of complex organic phosphate esters.

Examples of useful cationic surfactants include alkylamine salts such as laurylamine acetate, quaternary ammonium salts such as lauryl trimethyl ammonium chloride and alkyl benzyl dimethylammonium chlorides, and polyoxyethylenealkylamines. Examples of the amphoteric surfactants are alkylbetaines such as lauryl-betaine.

Examples of nonionic surfactants which can be used in this invention are polyethers, e.g., ethylene oxide and propylene oxide condensates which include straight and branched chain alkyl and alkaryl polyethylene glycol and polypropylene glycol ethers and thioethers; alkylphenoxypoly(ethyleneoxy) ethanols having alkyl groups containing from about 7 to about 18 carbon atoms and having from about 4 to about 240 ethyleneoxy units, such as heptylphenoxypoly(ethyleneoxy) ethanols, nonylphenoxypoly(ethyleneoxy) ethanols; the polyoxyalkylene derivatives of hexitol including sorbitans, sorbides, mannitans and mannides; partial long-chain fatty acids esters, such as the polyoxyalkylene derivatives of sorbitan monolaurate, sorbitan monopalmitate, sorbitan monostearate, sorbitan tristearate, sorbitan monooleate and sorbitan trioleate; the condensates of ethylene oxide with a hydrophobic base, said base being formed by condensing propylene oxide with propylene glycol; sulfur containing condensates, e.g., those prepared by condensing ethylene oxide with higher alkyl mercaptans, such as nonyl, dodecyl, or tetradecyl mercaptan, or with alkylthiophenols wherein the alkyl group contains from about 6 to about 15 carbon atoms; ethylene oxide derivatives of long-chain carboxylic acids, such as lauric, myristic, palmitic, or oleic acids or mixtures of acids, such as tall oil fatty acids; ethylene oxide derivatives of long-chain alcohols such as octyl, decyl, lauryl, or cetyl alcohols; and ethylene oxidelpropylene oxide copolymers sold under the tradename Pluoronics™.

A particularly useful surfactant which can be used in this invention is a nonionic surfactant which is an organosilanol derivative of tung oil, or linseed oil, or high erucic acid rapeseed oil. These surfactant compositions particularly feature high surface activity in forming stable emulsions of organic/water of various difficultly emulsifiable materials as compared with conventional emulsifying agents. These silanol-based surfactant compositions are described in copending, commonly assigned patent application Ser. No. 08/39,850, filed Oct. 30, 1996 now U.S. Pat. No. 6,404, 669. Another class of preferred surfactants are those which are copolymerizable with the monomers described hereinabove.

The amounts of surfactants employed in the emulsion polymerization process will range from about 0.01 to about 10 weight percent, preferably about 0.2 to about 5 weight percent based on the total weight of monomers and water.

The compositions of the present invention may contain in addition to the polymeric resins and metal driers referred to hereinabove, as required, suitable additives such as protective colloids, fillers, coloring agents, antiseptics, biocides, dispersing agents, thickening agents, thixotropic agents, antifreezing agents, and pH adjusting agents.

Examples of protective colloids are partially and fully hydrolyzed polyvinyl alcohol, hydroxyethyl cellulose, hydroxymethyl cellulose, ethylhydroxyethyl cellulose, carboxymethyl cellulose, ethoxylated starch derivatives, polyacrylic acid, alkali metal polyacrylates, polyacrylamide, poly(methyl vinyl ether/maleic anhydride), polyvinylpyrrolidone, water soluble starch, glue, gelatin, water soluble alginates, guar, gum arabic and gum tragacanth. The amounts of protective colloids used in the composition varies depending upon the intended application and generally ranges from about 0.1 weight percent to about 2 weight percent based on the total weight of the composition.

Examples of fillers include talc, calcium carbonate, diatomaceous earth, mica, kaolin, barium sulfate, magnesium carbonate, Aerosil, vermiculite, graphite, alumina, silica and rubber powder. Such coloring agents as titanium dioxide and carbon black can also be used as the fillers. The amount of the filler may be properly selected, and when used, for example, ranges from about 10 weight percent to about 50 weight percent based on the total weight of the composition of the present invention.

Various organic pigments and inorganic pigments may be broadly used as the coloring agents, but non-toxic anticorrosive pigments are preferred. Examples of such pigments are phosphate-type anticorrosive pigments such as zinc phosphate, calcium phosphate, aluminum phosphate, titanium phosphate, silicon phosphate, and ortho- and fused phosphates of these; molybdate-type anticorrosive pigments such as zinc molybdate, calcium molybdate, calcium zinc molybdate, potassium zinc molybdate, potassium zinc phosphomolybdate and potassium calcium phosphomolybdate; and borate-type anticorrosive pigments such as calcium borate, zinc borate, barium borate, barium meta-borate and calcium meta-borate. The amount of the coloring agent used may also be properly selected based on the end-use application of the compositions of the present invention.

Examples of the antiseptics are pyrrole compounds, imidazole compounds, thiazole compounds, pyridine compounds and organic halogen compounds. The amount of the antiseptic can be suitably selected, and is, for example, up to about 4 percent by weight based on the total weight (as solids content) of the composition.

Examples of the biocides, which are used either as wet-state protectors (i.e., in-can protectors) or as film protectors of a coating composition, are a wide variety of bactericides, fungicides or algicides, and include, without limitation, zinc oxide, cuprous oxide, organotin pigments, copolymers of organotin esters of methacrylic acid with conventional acrylates, tributyl tin oxide, and mixtures thereof Other examples of biocides particularly useful as in-can protectors are oxazoladines, organosulfurs, and benzisothiazolins. Any general toxic agent may be suitable as a biocide.

The dispersing agents may, for example, be inorganic dispersing agents such as sodium salts of polycarboxylic acids, sodium or ammonium salt of fused naphthalene sulfonate, polyoxyalkylene alkyl ethers of phenol ether, sorbitan fatty acid esters, polyoxyalkylene fatty acid esters, glycerin fatty acid esters, polyoxyethylene styrene phenol, sodium tripolyphosphate and sodium hexametaphosphate. As mentioned above, novel organosilanol derivatives of tung oil, or linseed oil, or high erucic acid rapeseed oil which are useful as surfactants are also suitable as dispersing agents. The amount of the dispersing agent can again be properly selected depending on the end application of the composition, and may range up to about 10 weight percent based on the total weight of the composition.

The thickening and thixotropic agents may be one and the same or different and may be the same as the protective colloids referred to hereinabove. Examples of thickening or thixotropic agents are polyvinyl alcohol, cellulose derivatives such as hydroxyethyl cellulose, hydroxypropyl cellulose and carboxymethyl cellulose salt, polyether compounds, urethane-modified polyether compounds, polycarboxylic acid compounds, sodium salts of polycarboxylic compounds, polyvinylpyrrolidone, polyoxyethylene derivatives such as polyethylene glycol ether and polyethylene glycol distearate, sodium alginate and inorganic materials such as sodium silicate and bentonite. The amounts of the thickening or the thixotropic agents can be properly chosen depending upon the type of end-application of the composition of the present invention.

Examples of the pH adjusting agents are sodium hydroxide, potassium hydroxide, sodium hydrogen carbonate, ammonia, triethanolamine, and β-dimethylaminoethanol. The amount of the pH adjusting agent may be a suitable one which is sufficient to adjust the pH of the composition to a desired value.

Various other additives having functional applications in coatings which are well known to those skilled in the art may also be used with the compositions of the present invention. Specific examples of such functional additives are corrosion inhibitors, ultraviolet light stabilizers, antioxidants, and the like.

As stated earlier, by incorporation of the internally plasticizing monomers (i.e., I) into compositions of the present invention, the compositions exhibit lower METs and cure to resins having T_(g)s significantly higher than the MFTs. A further significance of this invention is the capability of tailoring the glass transition temperature (T_(g)) of the emulsion polymers and the MFTs of the compositions formed therefrom. The MFTs of a coating composition is determined experimentally by using an apparatus described by Protzman et al. in J. Appl. Polymer Sci., 4, 81 (1960) incorporated herein by reference in its entirety. This apparatus is essentially an aluminum slab in which a constant and uniform temperature gradient may be maintained. The coating composition to be measured is spread uniformly in one of several sample wells. The point at which the film becomes discontinuous when dry is observed and this temperature is recorded as the MFT. To ensure that the films are actually continuous when formed above the MFT, the films are scrapped with a knife edge moving in the direction from low to high temperature. Below the MFT the material chips off the bar easily but above the MFT the coating does not lift off the bar. The transition between easily chipped to strong coating takes place at the MFT.

Conventional latex polymers generally feature MFTs closer to their T₈. Contrary to this conventional norm, the compositions of the present invention exhibit MFTs much below the final T_(g) of the cured and crosslinked emulsion polymer contained therein, thus eliminating the need for a plasticizer which is generally a volatile organic compound (VOC). Particularly, the compositions of the above mentioned preferred embodiment forms film at low MFTs ranging from about −5 to about 10° C. and cures to a resin having a T_(g) higher than 25° C.

The compositions of the present invention are particularly useful as coatings, adhesives, and inks formulations. A wide variety of coating formulations may be formed from the compositions of this invention. In general, the coating compositions are formed by incorporating the emulsion polymers formed from the internally plasticizing compound with one or more of the copolymerizable monomers described hereinabove. In addition, the coating compositions contain at least one drier and a surfactant, and as required, one or more of the additives described hereinabove.

The coatings produced by the cure of the internally plasticizing compound of this invention are useful in a wide variety of applications, i.e., architectural, decorative, maintenance, or industrial coatings. For example, in the electronics area these materials have applications as non-conductive coatings, e.g., solder masks for circuit boards or moisture resistant coatings for the boards or optical fibers.

Similarly, the compositions of the present invention may be formulated into a wide variety of adhesives and inks formulations having a diverse variety of applications. For example, in inks formulations the emulsion polymers of this invention are useful as binders. In general ink formulations differ from coating formulations in terms of the amounts of crosslinking monomers used, i.e., ink formulations generally contain higher amounts of the crosslinker. In addition, ink formulations may contain higher amounts of driers and drier accelerators for fast drying of these formulations. Accordingly, an ink formulation containing the emulsion polymers of this invention may be obtained by adding one or more pigments to the emulsion in accordance with a well-known method. The compositions of this invention may also be employed in forming radiation curable formulations, for example, UV curable high gloss coatings, inks, and adhesives formulations.

An adhesive formulation containing the emulsion polymers of this invention may similarly be obtained in accordance with a well -known method. Typically, an adhesive formulation may be formed using the emulsion polymer of this invention in combination with one or more of surfactants, protective colloids, and one or more of various other additives discussed hereinabove. The adhesive formulations of this invention are particularly suitable in the form of emulsion and/or aqueous solution, however, dry-mix, hot-melt, or solutions in organic solvent can also be formed using the polymers of this invention. A detailed description of adhesive formulations can be found in “Handbook of Adhesives,” 2nd Ed., edited by I. Skiest, Chapter 28, pp 465-494 (1977), Van Nostrand Reinhold Co., incorporated herein by reference in its entirety.

In a further aspect the invention provides a process for the formation of a waterborne formulation for coatings, inks or adhesives containing a latex formed from a substituted long-chain alkenol ester of an ethylenically unsaturated carboxylic acid comprising the steps of:

-   -   (a) subjecting a substituted long-chain alkenol to suitable         esterification conditions in the presence of an ethylenically         unsaturated carboxylic acid or its suitable derivative for a         sufficient period of time and under suitable conditions of         temperature and pressure to form the corresponding ethylenically         unsaturated ester of a long-chain alkenol;     -   (b) subjecting said ester of a long-chain alkenol (monomer) to         suitable polymerization conditions in the presence of at least         one other ethylenically unsaturated copolymerizable monomer for         a sufficient period of time and under suitable conditions of         temperature and pressure to form the corresponding polymer         dispersed in an aqueous phase; and     -   (c) blending said dispersion of said polymer with at least one         drier selected from the group consisting of aliphatic carboxylic         acid salts of cobalt, manganese, lead, zirconium, calcium, and         mixtures thereof, and in the presence of at least one ionic or         non-ionic surface-active agent to form the formulation.

The starting material, i.e., the long-chain alkenol is the same compound as described hereinabove and is of the formula II.

Where R₁, R₂, R₃, R4, R₅, R6, and R₇ are as defined above.

The esterification reaction of II and an ethylenically unsaturated carboxylic acid or its derivative III may be carried out using any of the well-known methods in the art. In the structure III R₈, R₉, and R₁₀ are as defined above. X is selected from the group consisting of Br, Cl, hydroxy, alkoxy group having 1 to 4 carbon atoms, and acyloxy group same as the acyloxy group derived from said ethylenically unsaturated 10 carboxylic acid or an acyloxy group having 2 to 4 carbon atoms as described hereinabove.

Accordingly, the esterification reaction in the step (a) of the process of the present invention may be generically represented as follows:

In this schematic representation, R′—CO is an acyl group of the ethylenically unsaturated carboxylic acid or its derivatives of formula III, R″O- refers to the alkoxy group and R″′—COO refers to the acyloxy group mentioned hereinabove. In most instances the esterification reaction is carried out by using one mole of the acid or its derivative m per mole of hydroxy group present in II. However, it may be desirable to use one of these starting materials in excess of the other in some cases.

The preferred ethylenically unsaturated carboxylic acid and its derivatives III are either acrylic or methacrylic derivatives, i.e., R₈ and R₉ are hydrogen and R₁₀ is either methyl or hydrogen in III. Accordingly, the preferred acryloyl or methacryloyl compound used to esterify the long-chain alkenol II is a halide such as acryloyl chloride, methacryloyl chloride, acryloyl bromide, and methacryloyl bromide. Various other acryloyl or methacryloyl derivatives that may be employed in this esterification reaction include acrylic acid, methacrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-propyl acrylate, butyl acrylate, acrylic anhydride, methacrylic anhydride, mixed anhydrides of acrylic and acetic acids, and the like.

The esterification reaction may be carried out with or without any catalysts. However, in some cases it is preferable to carry out the esterification reaction in the presence of a suitable acid, base or metal catalysts. Any acid, base or metal catalyst that will function as a catalyst for the esterification conditions may be used in this step (a) of the process of the present invention. Specific examples of such esterification reactions may be found in U.S. Pat. No. 4,745,213 and U.S. Pat. No. 5,243,069, incorporated herein by reference in their entirety.

The suitable acid includes, without limitation, mineral acids such as HCl and H₂SO₄; super acids such as hydrofluoric acid, fluorosulfonic acid; organic sulfonic acids such as p-toluene sulfonic acid, methane sulfonic acid, and trifluoromethane sulfonic acid; other inorganic acids such as phosphoric acid, and boric acid; carboxylic acids such as trifluoro acetic acid; Lewis acids such as BF₃, AlCl₃, SbF₅, and the like; and solid acid catalysts such as silica, zeolites, and the like. The suitable base includes an inorganic base such as a metal hydroxide, preferably an alkali metal hydroxide, an alkali metal carbonate, e.g., K₂CO₃; an alkali metal alkoxide (an ionic organic base), such as NaOCH₃, KOC(CH₃)₃, etc.; an alkali metal organic salt (an ionic organic base) such as potassium acetate, etc.; and an amine (a non-ionic organic base) such as pyridine, or a tri-lower-alkylamine, e.g., tripropylamine, trimethylamine, triethylamine, an hindered base such as 2,4-diazabicyclo[2,2,2]octane, etc. Ammonia can also be used as a base in step (a) of the process of the present invention.

Illustrative examples of metal catalysts that are particularly suitable in the transesterification type reactions (i.e., Eq. 2) include derivatives of Group I metals, derivatives of Group IVA metals, derivatives of Group IVB metals, derivatives of manganese and cobalt, and mixtures thereof These may be preferably lithium acetate, sodium acetate, potassium acetate, cesium acetate, stannic acid, butylstannoic acid, stannous octanoate, dibutyltin oxide, tin butoxide, dibutyltin diesters, di-n-butyl tin dilaurate, titanium tetrabutoxide, titanium propoxide, titanium phenoxide, zirconium butoxide, silicon phenoxide, manganese acetate, cobalt acetate, and mixtures thereof.

The amount of the catalyst employed depends upon the nature of the esterification reaction and the catalyst. Any amount of catalyst that would be sufficient to carry out the desired esterification reaction may be used and may range from about 30 parts per million to one to two moles of catalyst per mole of the acid or its derivative III used in this reaction.

The temperature at which step (a) is conducted ranges from about −10° C. to about 150° C., preferably from about 10° C. to about 100° C. The pressure in this step (a) is not critical and can be subatmospheric, atmospheric, or super atmospheric.

The reaction times in step (a) will generally range from about 15 minutes to about 6 hours or longer and sometimes under an inert atmosphere such as nitrogen.

Using the procedure of step (a) outlined herein, the long-chain alkenol II undergoes esterification reaction with carboxylic acid or its derivatives III to form the corresponding ethylenically unsaturated ester of a long-chain alkenol I.

In step (b) of the process of the present invention the olefinic monomer I is subjected to suitable emulsion polymerization conditions in the presence of one or more of suitable copolymerizable monomers having at least one polymerizable ethylenically unsaturated double bond. The suitable copolymerizable monomers of this invention are those which are described hereinabove. The polymerization of these monomers emulsified in water can be carried out using conventional emulsion polymerization procedures. Typically such polymerization reactions are carried out in the presence of one or more anionic, cationic, amphoteric, or nonionic surfactants. The suitable surfactants are those which are described hereinabove.

The monomers, i.e., the monomer I and the copolymerizable monomers of this invention are polymerized by means of a catalytic amount of a conventional free radical polymerization catalyst or catalyst system (which can also be referred to as an addition polymerization catalyst, a vinyl polymerization catalyst, or a polymerization initiator), preferably, one which is substantially water soluble. Among such catalysts are peroxides, such as hydrogen peroxide, tertiary butyl hydroperoxide, cumene hydroperoxide; alkali metal (e.g., sodium, potassium, or lithium), and ammonia persulfates, perphosphates, and perborates; azo nitriles, such as α,α-azobisisobutyronitrile, and water soluble azo initiators, such as WAKO™ initiators; and redox system including such combinations as mixtures of hydrogen peroxide, t-butyl hydroperoxide or the like, and any of the iron salts, titanous salts, zinc formaldehyde sulfoxylate, or sodium formaldehyde sulfoxylate; alkali metal or ammonium persulfate, perborate, or perchlorate together with an alkali metal bisulfite, such as sodium metabisulfite; and alkali metal persulfate together with an aryl phosphinic acid such as benzene phosphinic acid and the like. The free radical initiators may be activated either by a thermal or a redox source depending upon the nature of the initiators employed.

The temperature at which step (b) is conducted ranges from about 10° C. to about 90° C., preferably from about 20° C. to about 75° C. The pressure in this step (b) is not critical and can be subatmospheric, atmospheric, or super atmospheric.

The reaction times in step (b) will generally range from about 1 hour to about 6 hours or longer and sometimes under an inert atmosphere such as nitrogen.

Using the procedure of step (b) outlined herein, the ethylenically unsaturated derivative of a long-chain olefinic monomer I undergoes polymerization reaction with one or more of copolymerizable monomers to form the polymers dispersed in water.

In step (c) of the process of this invention the polymer so formed in step (b) still dispersed in water is further blended with at least one or more of a metal drier, surfactant, and desired combinations of the additives to form the waterbome formulations suitable for use in coatings, adhesives or inks applications. For instance, the suitable metal driers, surfactants, and various additives are those described hereinabove. The amounts of these components used depend on the intended use of the formulation and generally range in amounts as described hereinabove.

The blending in step (c) can be carried out in any of the mixing/blending devices generally known in the art. The temperature at which the blending is conducted is generally around ambient conditions, and ranges from about 10° C. to about 40° C. The reaction times for blending generally range from about 10 minutes to about 60 minutes and sometimes under an inert atmosphere such as nitrogen.

In one of the specific embodiments, a process for the formation of a latex containing acrylate or methacrylate ester of a long-chain alkenol is also provided. The step (a) in this specific embodiment is same as the step (a) discussed above. In the step (a) of this embodiment, a long-chain alkenol IV is subjected to esterification conditions in the presence of a substituted acrylic acid or its derivatives V. In structure IV, a, a′, b, and c are integers, where a, and c have a value of from 3 to 10, a′ has a value of from 0 to 10, and b has a value of 1 or 2.As mentioned hereinabove, the esterification reaction may be carried out using any of the well-known methods known in the art. The esterification reaction may be carried out with or without catalysts. If catalyst is used, any acid, base or metal catalyst that will function as a catalysts for the esterification conditions may be used.

The preferred acrylic derivatives V that may be employed in the esterification reaction are those in which R₁₀ is either hydrogen or methyl and X is —Cl, —Br, —OH, or —OCH₃. Accordingly, the preferred acrylic derivatives V that may be employed to form the acrylate or methacrylate esters of fatty alcohols are acryloyl chloride, acryloyl bromide, methacryloyl chloride, methacryloyl bromide, acrylic acid, methacrylic acid, methyl acrylate, and methyl methacrylate.

The temperature at which step (a) is conducted ranges from about −10° C. to about 150° C., preferably from about 10° C. to about 100° C. The pressure in this step (a) is not critical and can be subatmospheric, atmospheric, or super atmospheric.

The reaction times in step (a) will generally range from about 15 minutes to about 6 hours or longer and sometimes under an inert atmosphere such as nitrogen.

Using the procedure of step (a) outlined herein, the alkenol IV undergoes esterification reaction with carboxylic acid or its derivatives V to form the corresponding acrylate or methacrylate ester of a long-chain alkenol VI.

In step (b) the acrylate ester of the alkenol VI is subjected to emulsion polymerization conditions in the presence of one or more of polymerizable comonomers. This step (b) is same as the step (b) of the process of making a latex containing the ester of a substituted long-chain alkenol I described hereinabove. The polymerizable comonomers are those which are described hereinabove.

The temperature at which step (b) is conducted ranges from about 20° C. to about 75° C. The pressure in this step (b) is not critical and can be subatmospheric, atmospheric, or super atmospheric.

The reaction times in step (b) will generally range from about 1 hour to about 6 hours or longer and sometimes under an inert atmosphere such as nitrogen.

Using the procedure of step (b) outlined herein, the acrylate ester of the alkenol VI undergoes polymerization reaction with copolymerizable monomers to form the polymer dispersed in water.

The step (c) of this specific embodiment is same as the step (c) of the process of making coatings, adhesives, and inks formulations described hereinabove. In this step (c) of the process of this specific embodiment the polymer so formed in step (b) still dispersed in water is further blended with at least one or more of a metal drier, surfactant, and desired combinations of the additives to form the waterborne formulations suitable for use in coatings, adhesives, or inks applications.

As mentioned hereinabove, the compositions of this invention have utility in a diverse variety of applications. For instance, the compositions of this invention can be converted to redispersible latex powder by physical drying of the latex composition. The compositions of this invention can also be used to form solvent-free coatings such as adhesives, including pressure sensitive and contact adhesives, which can be used either at ambient or elevated temperatures. The inks or coatings formulations formed from the compositions of this invention may be in the form of waterborne latex or may be in the form of 100% solids. A significant advantage of these compositions is that the coatings, inks, and adhesives formed from these compositions are essentially solvent and VOCs free formulations, thus eliminating environmental pollution yet featuring enhanced properties.

This invention is further illustrated by the following examples which are provided for illustration purposes and in no way limit the scope of the present invention.

EXAMPLES General

In the Examples that follow, the following abbreviations are used:

-   -   T_(g)-Glass transition temperature.     -   NMR-Nuclear magnetic resonance spectroscopy, usually of either         proton, ¹H; and/or carbon 13^(, 13)C nuclei.     -   IR-Infrared spectroscopy.     -   DSC-Differential Scanning Calorimetry.     -   MFT-Minimum film forming temperature.     -   PVC-Pigment volume concentration.     -   VOC-Volatile organic content         General Analytical Techniques Used for the Characterization: A         variety of analytical techniques are used to characterize         various starting materials and the compositions of this         invention which include the following:         NMR: ¹H and ¹³C NMR spectra are recorded on a Bruker AX-200 MHz         spectrometer with 5 mm probes at 200 and 50 MHz, respectively.         DSC: A Mettler DSC-30 is used to determine the T_(g) of the         films (mid point value). The heating rate is maintained at 10°         C./minute, generally, over a temperature range of −50° C. to         100° C. The flow rate of nitrogen or air is maintained at 20         mL/min.         MFT: MFT of latexes are determined by a MFFT Bar 90 equipment         from Byk-Gardner in accordance with ASTM procedure No. D-2354.         Particle Size Determination: Particle size is measured by a         Coulter N4 MD sub-micron particle size analyzer.         Tensile Strength Measurements: The tensile strength and percent         elongation of the films are determined with a 810 Material Test         System according to ASTM D-2370. The specimen are cut to a width         of 13 mm, a thickness of 0.06-0.12 mm, and a gauge length of         15 mm. In most cases, the data reported represents an average of         8 measurements.

Example 1

Pentadeca-12-ene-1-ol (22.6 grams) is placed in a three-neck flask under a blanket of nitrogen. The entire reaction contents are cooled in an ice bath. Methacryloyl chloride (10.5 grams) dissolved in about 50 mL of methylene chloride is added slowly to the cooled pentadeca-12-ene-1-ol with vigorous stirring in about 2 hours. Triethylarnine (11.5 g) dissolved in 25 mL of methylene chloride is subsequently added in about an hour. After addition of triethylamine, the solution is allowed to warm to ambient temperature and is stirred for another 4 hours in order to complete the reaction. The precipitated triethylammonium chloride is removed by filtration, and the filtrate is washed with brine solution (saturated NaCl) followed by washings with dil. NaOH and dil. HCl. The organic layer is dried with anhydrous magnesium sulfate and the solvent is removed in vacuo to yield pentadeca-12-ene-1-yl methacrylate in good yields. Pentadeca-12-ene-1-yl methacrylate is stabilized from polymerization by addition of approximately 10 ppm hydroquinone. The structure of the product is verified by ¹H and ¹³C NMR spectroscopy.

Example 2

Example 1 is substantially repeated in Example 2 with the exception that the reaction is carried out using acryloyl chloride and pentadeca-12-ene-1-ol as follows. 22.6 grams of pentada-12-ene-1-ol is reacted with 9.1 grams of acryloyl chloride in the presence of 11.5 grams of triethylamine. The product is characterized by ¹H and ¹³C NMR spectroscopy.

Example 3

This Example 3 illustrates the preparation of a latex containing the internally plasticizing long-chain alkenol ester monomer of this invention. To a 1 L reactor kettle equipped with an impeller and charged with 110 grams of deionized (DI) water, which is deoxygenated (DO) for about half an hour by heating to 80° C. under a nitrogen atmosphere, is added polyvinyl alcohol (80 grams of 10% solution) followed by the addition of 12 grams of Igepal CA-897 (octylphenol ethoxylates with 40 moles of ethylene oxide units obtained from Rhone-Poulenc), 1.2 grams of Igepal CA-630 (octylphenol ethoxylates with 9 moles of ethylene oxide units obtained from Rhone-Poulenc), and 0.6 grams of sodium bicarbonate. The contents are maintained at 80° C. under a blanket of nitrogen, and the preseeding is affected by the addition of ammonium persulfate (0.6 grams) and vinyl acetate (40 grams), and increasing the impeller speed to 200 rpm.

After 15 minutes of preseeding a monomer mixture or pre-emulsion (a stable pre-emulsion can be obtained by mixing all the desirable monomers, surfactants and water over a stir plate for few minutes) consisting of 30 grams of pentadeca-12-ene-1-yl methacrylate (prepared in accordance with Example 1) and 130 grams of vinyl acetate is added over a period of 3.5 hours at 75° C. maintaining the impeller speed at 200 rpm. Additional amounts of ammonium persulfate (0.6 grams) dissolved in 30 grams of DI water is cofed into the reactor over a period of 3.75 hours. After the addition of all of the monomers and initiators, the contents of the reactor are stirred at 150 rpm for an additional period of 2 hours at 80° C. The cooled latex is filtered from a cheese cloth or a medium mesh filter and poured into a clean container for further evaluation.

Examples 4 and 5

Example 3 is substantially repeated in Examples 4 and 5 with the exception that the latex is prepared using the following amounts of materials in each of these examples:

Example 4 Example 5^(c) 10% Polyvinyl alcohol 40 grams 60 grams Igepal CA-897 (Rhone Poulenc) 12 grams 12 grams Igepal CA-630 (Rhone Poulenc) 1.2 grams 1.2 grams NaHCO₃ 0.8 grams 0.8 grams DI, DO water 150 grams 140 grams Ammonium persulfate 0.6 grams 0.2 grams Vinyl acetate - for seeding 40 grams — Vinyl acetate - with monomer emulsion 114 grams 147 grams Pentadeca-12-ene-1-yl methacrylate^(a) — 16 grams Pentadeca-12-ene-1-yl acrylate^(b) 16 grams — Butyl acrylate 30 grams 34 grams Sipomer WAM II (Rhone Poulenc) — 3 grams Ammonium persulfate - initiator feed 0.6 grams 0.8 grams DI, DO water - for initiator feed 30 grams 30 grams ^(a)from Example 1; ^(b)from Example 2.

In both examples, the seeding is done at 80° C. for about 10 minutes, and the polymerization itself is conducted at 72° C. The monomers are added during a period of about 3.5 hours at an impeller speed of 200 rpm, along with the initiator cofed for about 3.75 hours, and post polymerized for about 1.5 hours.

The films are formed in these examples with and without the addition of metal driers. The samples with metal driers contain 0.08 weight percent (based on solids) of cobalt hydro-cure II (obtained from OMG, Inc., Cleveland, Ohio) as a metal drier, 0.5 weight percent (based on solids) DRI-RX (obtained from OMG, Inc., Cleveland, Ohio) as a drier accelerator, and I weight percent methyl ethyl ketone peroxide as a free radical initiator.

Example 6

Examples 6 illustrates the formation of the Mill Base formulations used for the preparation of coatings compositions. Specified amounts of the ingredients given below are added to a Lightnin mixer at a mixing speed of 800 rpm, and mixed further at 3500 rpm for 20 minutes.

Ingredients Example 6 Tronox CR-800 (Kerr McGee) 455 grams Huber 70C (DuPont) 292.5 grams Beaverwhite 325 (ECC) 260 grams Duramite (ECC) 325 grams Natrosol Plus (Aqualon) 12 grams Kathon LX 1.5% (Rohm & Haas) 5 grams KTPP (Aldrich) 6.5 grams Byk 034 (Byk Chemie) 12 grams Tamol 731 25% (Rohm & Haas) 39 grams Surfymol 465 (Air Products) — DI water 715 grams

Examples 7 and 8

The Examples 7 and 8 illustrate the formation of coatings compositions using the polymeric latices of this invention. The latices formed in Examples 4 and 5 are used in these Examples to form the vinyl-acrylic latex coatings compositions. The coatings are pigmented at 55% pigment volume concentration (PVC) using the Mill Base formulation of Example 6. The ingredients and the respective amounts for forming the coatings compositions are given below. The following coatings compositions are prepared using a Lightnin mixer set at 200 rpm.

Ingredients Example 7 Example 8 Example 6 - Mill Base Formulation 180 grams 180 grams DI water 30 grams 22 grams Na₂CO₃ (20%) 6 grams 7 grams Byk 035 (Byk Chemie) 0.4 grams 0.4 grams Surfynol 465 (Air Products) 1 gram 1 gram Latex Example 4 Example 5 % solids 45 43 Amount 87 grams 92 grams Rompaque OP - 62 LO (36.5%) 20 grams 20 grams (Rohm & Haas) Polyphobe 107 (25%) 0.8 grams 1.2 grams (Union Carbide) Polyphobe 102 (25%) 5 grams 6 grams (Union Carbide)

Coating films are cast onto Leneta charts, aluminum and steel panels, and the film properties are evaluated.

Example 8

This Example 9 illustrates the use of the internally plasticizing monomer of this invention directly in an UV curable formulation. An ink formulation is made using pentadeca-12-ene-1-yl acrylate formed in accordance with Example 2 as follows. Specified amounts of the ingredients as given below are blended in a Lightnin mixer at 150 rpm for one hour and then to insure thorough mixing the ingredients are transferred to a ball mill and ground to a Hegman #7.

Ingredients Parts by weight Pentadec-12-ene-1-yl acrylate, from Example 2 21.4 Fluorescent rocket red AX-135 (Day Glo Color) 1.0 Photomer 3016 (Henkel) 17.0 Photomer 4061 (Henkel) 19.0 Photomer 4094 (Henkel) 15.6 Photomer 4149 (Henkel) 4.4 Photomer 4770 (Henkel) 5.5 Byk 065 (Byk (Chemie) 0.4 Byk 358 (Byk Chemie) 0.3 Byk 325 (Byk Chemie) 0.3 Irgacure 651 (Ciba) 2.7 Benzophenone 1.3

A 2 mil thick film is applied onto wood, aluminum, paper and steel panels with a draw bar, and irradiated under a 600 W medium pressure mercury UV lamp for 4 seconds at a distance of approximately 7″ with a Fusion UV curing source to a hard, smooth film. Similar formulations and applications can be developed using other specialty monomers described herein.

Although the invention has been illustrated by certain of the preceding examples, it is not to be construed as being limited thereby; but rather, the invention encompasses the generic area as hereinbefore disclosed. Various modifications and embodiments can be made without departing from the spirit and scope thereof 

1. A process for the formation of a waterbome formulation for coatings, inks or adhesives containing a latex formed from a long-chain alkenol ester of an ethylenically unsaturated carboxylic acid comprising the steps of: (a) subjecting a long-chain alkenol to suitable esterification conditions in the presence of an ethylenically unsaturated carboxylic acid or its derivative for a sufficient period of time and under suitable conditions of temperature and pressure to form an ethylenically unsaturated ester of a long-chain alkenol; (b) subjecting said ester of a long-chain alkenol to suitable polymerization conditions in the presence of at least one other ethylenically unsaturated copolymerizable monomer for a sufficient period of time and under suitable conditions of temperature and pressure to form a polymer dispersed in an aqueous phase; and (c) blending said dispersion of said polymer with at least one drier selected from the group consisting of aliphatic carboxylic acid salts of cobalt, manganese, lead, zirconium, calcium, and mixtures thereof, and in the presence of at least one ionic or non-ionic surface-active agent to form the formulation.
 2. The process as set forth in claim 1 wherein said alkenol has the formula:

wherein (a) R₁, R₂, R₃, R4, R₅, R6, and R₇, are the same or different and are each independently selected from the group consisting of: hydrogen; alkoxy group having 1 to 10 carbon atoms; alkoxyalkyl group having 1 to 10 carbon atoms; and linear or branched alkyl and fluoroalkyl groups having the formula C_(n)H_(x)F_(y), where n is an integer from 1 to 10, x and y are integers from 0 to 2n+1, and the sum of x and y is 2n+1; and (b) a, b, and c, are integers, where a and c have a value of from 0 to 20, and the sum of a and c is at least 8, and b has a value of 1 or
 2. 3. The process as set forth in claim 1 wherein said ethylenically unsaturated carboxylic acid or its derivative has the formula:

wherein (a) R₉, R₁₀, and R₁₁ are the same or different and are independently selected from the group consisting of: hydrogen; a carboxylate of the formula —COOR, where R is an alkyl group having 1 to 10 carbon atoms, phenyl or substituted phenyl; phenyl or substituted phenyl; tolyl or substituted tolyl; benzyl or substituted benzyl; a linear or branched alkenyl group having 2 to 10 carbon atoms; and linear or branched alkyl and fluoroalkyl groups having the formula C_(n)H_(x)F_(y), where n is an integer from 1 to 10, x and y are integers from 0 to 2n+1, and the sum of x and y is 2n+1; and (b) X is selected from the group consisting of: Br; Cl; hydroxy; an alkoxy group having 1 to 4 carbon atoms; and an acyloxy group having 2 to 4 carbon atoms.
 4. The process as set forth in claim 1 wherein said long-chain alkenol ester has the formula:

wherein (a) R₁, R₂, R₃, R4, R₅, R₆, and R₇, are the same or different and are each independently selected from the group consisting of: hydrogen; an alkoxy group having 1 to 10 carbon atoms; an alkoxyalkyl group having 1 to 10 carbon atoms; and linear or branched alkyl and fluoroalkyl groups having the formula C_(n)H_(x)F_(y), where n is an integer from 1 to 10, x and y are integers from 0 to 2n+1, and the sum of x and y is 2n+1; (b) R₈, R₉, and R₁₀ are the same or different and are independently selected from the group consisting of: hydrogen; a carboxylate of the formula —COOR, where R is an alkyl group having 1 to 10 carbon atoms, phenyl or substituted phenyl; phenyl or substituted phenyl; tolyl or substituted tolyl; benzyl or substituted benzyl; a linear or branched alkenyl group having 2 to 10 carbon atoms; and linear or branched alkyl and fluoroalkyl groups having the formula C_(n)H_(x)F_(y), where n is an integer from 1 to 10, x and y are integers from 0 to 2n+1, and the sum of x and y is 2n+1; and (c) a, b, and c, are integers, where a and c have a value of from 0 to 20, and the sum of a and c is at least 8, and b has a value of 1 or
 2. 5. The process as set forth in claim 1 wherein in step (a) the temperature is from about −10° C. to about 150° C. and the pressure is atmospheric; in step (b) the temperature is from about 10° C. to about 90° C. and the pressure is atmospheric; and in step (c) the temperature is from about 10° C. to about 40° C. and the pressure is atmospheric.
 6. The process as set forth in claim 1 wherein in step (b) the polymerization conditions include an initiator.
 7. The process as set forth in claim 1 wherein in step (b) said initiator is a free radical initiator which is activated either by a thermal, or redox source.
 8. A product produced in accordance with the process of claim
 1. 9. A process for preparing a latex coating composition containing a reaction product of an acrylate or methacrylate ester of a long-chain alkenol which comprises the steps of: (a) subjecting a long-chain alkenol of the formula:

to esterification conditions in the presence of a substituted acrylic acid or its derivatives of the formula:

at a temperature of about 10° C. to about 100° C. for a period of about 15 minutes to about 6 hours to form the corresponding acrylate or methacrylate ester of the fatty alcohol of the formula:

(b) subjecting said acrylate or methacrylate ester of a long-chain alkenol to emulsion polymerization conditions in an aqueous phase in the presence of one or more of polymerizable comonomers selected from the group consisting of vinyl acetate, vinyl chloride, vinyl ester of versatic acid, acrylic acid, acrylonitrile, acrylamide, butyl acrylate, butyl methacrylate, methyl acrylate, methyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, glycidyl acrylate, glycidyl methacrylate, and styrene; and a suitable free radical initiator at a temperature of about 20° C. to about 75° C. for a period of about 1 hour to 6 hours to form a polymer of said acrylate or methacrylate ester with said comonomers; and (c) blending said polymer with at least one metal drier selected from the group consisting of aliphatic carboxylic acid salts of cobalt, manganese, lead, zirconium, calcium, and mixtures thereof, and in the presence of at least one ionic or non-ionic surface-active agent to form the latex; wherein (i) R₁, R₂, and R₃, are the same or different and are each independently selected from the group consisting of: hydrogen; an alkoxy group having 1 to 10 carbon atoms; an alkoxyalkyl group having 1 to 10 carbon atoms; and linear or branched alkyl and fluoroalkyl groups having the formula C_(n)H_(x)F_(y), where n is an integer from 1 to 10, x and y are integers from 0 to 2n+1, and the sum of x and y is 2n+1; (ii) R₁₀ is either hydrogen or methyl; (iii) X is selected from the group consisting of: Br; Cl; hydroxy; an alkoxy group having 1 to 4 carbon atoms; and an acyloxy group having 2 to 4 carbon atoms; and (iv) a, a′, b, and c, are integers, where a, and c have a value of from 3 to 1 0, a′ has a value of from 0 to 10, and b has a value of 1 or
 2. 10. A product produced in accordance with the process of claim
 9. 